Metallic roofing



Jan. 12, 1965 J. R. BODDIE METALLIC ROOFING Filed Sept. 28, 1962 FIG. 5.

INVENTOR.

JOHN R. BODDIE struction a .FIG. 6is an isometriciview of ridge panels are formed;

United States Patent 3,164,929 METALLIC ROOFWG John R. Boddie, 7522 S. Santa Fe, R0. Box 60308,

- Houston, Tex. Filed Sept. 28, 1962, Ser. No. 226,851 6 Claims; (Cl. 50200) This is a continuation-in-part of US. patent application Serial No. 6,260, filed February 2, 1960, by John R. Boddie for Metallic Roofing.

This invention relates to the art of roofing, and mor particularly to roofing with interlocking metallic roof panels.

In the use of thin, interlocking sheet metal panels for roofing, considerable difficulty arises in making a watertight roof that is not subject to electrolytic decomposition,-

not subject to rattling by wind, and allows for simplicity of manufacture and assembly, Many attempts have been made in the past to provide metal-sheathed roofs having these qualities, but all have been found to be deficient in one or more of the above-recited qualities. Typical of the prior art are the roof constructions described in the following United States patents: No. 2,032,275, Fradette; No. 2,830,546, Rippe; No. 2,626,577, Roush et a1.

Accordingto one aspect of my invention, a metallic roofing panel is provided which is adapted for use with sheets .of asphaltic felt (a'resilient, pliable, waterproof roofing material) laid in overlapping layers on a substantially continuous inclined roof deck. The panel terminailing flange is-nailed to the underlying feltand roof deck, a layerof felt may be placed over the raised portion whereby the felt layer substantially fills the space galvanized steel also is adapted foruse with the invention. The panelmay be between 2.and 8 feet in length and may be corrugated so that the distance between valleys or peaks is approximately 20 times the thickness of the sheet metal; If the panel is corrugated, the depth of the corrugations should be between 1 and times the crimping it forward in a substantially 200 upper bendbetween the raised upper portion and the'nextpanel. In 7 this manner, the portion of the felt subject to water drain age is not perforated by'nails so thatit is impossible for water to penetrate the felt;- Weep "holes may be provided in the re-entrant hookto facilitate water drainage out of FIGS. 1 and 2 are fragmentary cross-sectional views of a roof constructionin accordance with my invention;

FIG. 3 is a fragmentary view'of a portion of the conof FIG. 1, illustratingthe lock details of the structure; k p

FIG. 4 is'an enlarged' side 'view of one of the metallic panels of FIG. 1, more perspicuously illustrating certain constructional details thereof;

FIG. 5 is atop view of two shingles joined by a cleat in accordance withthe invention; U

ridge .panels in accordance with the invention; j

FIG. 7 is a top'view of a metal blank fromrwhich the F168 is an enlarged fragmentary perspective view of a portion of the structure shown in FIG. 7; and i j FIG. .9 is a'perspective view of the cleat of FIG. 8

illustrated in its normal position. 5

The metallic roof panel 42 illustrated in FIG 1, 3, and

4 comprises =a body portiontl having a-downwar'dly extend ing re-entrant hook at one end thereof .andfan upwardly *extending' portion defining a notch orrecess'at the other erably between 77 and 83.

7 slightly less than 90, and preferably should be between 85 and 88?. The angle betweenthe downwardly extending portion 11 and the back-extending portion 12A 0f the re-entrant hook should be approximately 80, and pref- Thus, angle a between a plane parallel to body section 1 andback-extending section 12A will be'approximately 15, and preferably will be between 12 and 18. One or more weep holes 12 are provided at the juncture of portions 11 and 12A.

The upwardly extending portion at the upper end of the panel is formed by crimping theend oftthe panel back in an S-bend comprising a substantially 180 lower bend designated by the reference numeral 10, andthen designated by the "reference numeral 18. In this manner, a notch or recess 38 is formed which is adapted to receive the back-extending portion of the re-entrant hook of a similarly constructed panel. The endof the panelat the upper end of the S-bend extends beyondthe notch to forma nailing flange .39. i i

A As can best be seen'in FIG, 1, the metallic panel described above is. meant to cover a substantially continuous roof deck 7 along with felt layers 28, 40, 40A, vetc. The roofdeckmaybe formed of boards, as shown, or of wood shingles where an existing roof is to be covered; The felts may be conventional resilient, pliable, waterproof sheets of rag or similar fibrous material, thoroughly saturated and coated with weathered' asphalt. The felt functions to support the panels and provide the rigidity necessary to an sound deadener. v

An eave or starter strip 32 is, used to start the roof assembly. Theeave .s trip 32 has a full return lip 33 to which the re-entranthook of thefirst panel is hooked,"

a drip edge 34 turned out slightly to hold water away from the building and; to prevent capillary action from drawing water up between the eave strip and the build- 7 ingf The drip-lip 35 seryes to cover the edge of the roof deck to form a protective border around the roof edge and to flash water to the gutters. A fastening lip 36 ex tends over the edgeof the roof to permit the cave strip to be nailed to the roof deck. Y

The felts and 'panels are applied starting at the eave,

as can best be seen in FIG., 1. The first felt layer 28 is laid onthe eave, the starter strip 32-is nailed thereover, a feltjlayer 40 is nailed over'the eave strip, and the reentrant hook 29-of-the fir'st panel142Ais hooked over the return loop of the 'eave strip. The nailing flange 39 (see F1654) is then nailed to the roof deck 7 through the felt. The flange 39 need not be driven against the felt; itlhasybeen found best to leave a small 'gap between the'felt and the flange, particularly when wood shingles i I serve' as theroof deckg 'Another layer of felt 40Ais laid so that 'thei'ower edge thereof extends over the nailing flange and the notch down to the 200 bend 18 in the sheet metal '(see FIG. 1). The next panel 42B is applied" byhooking'the back-extending member int'o'the notch; As illustrated in FIG'..3, thenorrnalithickness of the felt prevent rattling, to' waterproof the assembly, and to act is at least as great, and preferably slightly greater than the space between the upwardly extending portion of the lower panel and the lower end 19 of the body portion 1 of the upper panel. When the re-entrant hook'of the upper panel is hooked into the notch of the lower panel, .the back-extending member 12A(see FIG. 4) contacts the lower panel at the points designated by the reference numerals 16 and 17. Thus, the portion of the lower panel at the 180 to 200 forward bend designated by the reference numeral 18 is forced down. Since the nailing flange 39 has been nailed, a very effective spring lock is formed. The lock holds the upper shingle securely in place against the felt and compresses the felt to prevent rattling of the panels. With reference to FIG. 1, the nailing flange of the upper panel is then nailed to the felt and the roof deck and the next and succeeding felt and panel members are applied in the same manner.

At the roof ridge (see FIG. 2), after the nailing fianges .39 of panels on both sides of the ridge have been nailed in place, a plurality of fibred ridge felt strips 30 are lapped over the ridge. Ridge shingles 31, which will be described in detail below with respect to FIGS. 6 and 7, are hooked in place and are nailed in place by nails 20. The ridge shingles 3l manifestly may be nailed through the topmost panels without affecting thewaterproof quality of the roof. A nailing apron or ridge flange 15 (see FIG. 6) is nailed in place tosecure the ridge panels to the roof.

FIGS. 6 and 7 illustrate the details of the Boston ridge shingles 31 in accordance with the teachings of the invention. At the lower edge 22 on each ridge is 're-entrant hook similar in design to that described with respect to the panel member described in FIG. 2. Each reentrant hook engages the recesses of ,the adjacent ridge member. A single lapped layer of felt lies over the ridge under the cover, as described above. Each cover section is formed from a sheet metal blank cut as shown in FIG. v7. The angle 18 of notch 26 is equal to the ridge angle of theroof covered. The blank also is cut on line 27 and is folded on lines 23 to form a re-entrant hook and notch similar to the hook and notch illustrated in FIG. 2. A nailing apron or ridge flange 15 secures the assembly at one end, and'a re-entrant hook secures the assembly at the opposite end. I

Abutting edgesof each pair'of adjacent panel members preferably are connected together as shown in FIGS. and 8 by expansion cleat 50. As illustrated in- FIGS. 8 and 9, each cleat is formed from one rectangular piece of sheet metal. The cleat comprises lower wings or flanges 53 and 61 extending upwardly and outwardly from a central webincluding portions 55 and 57. The top portion is bent backwardly upon itself to connect the web portions 55 and 57. The flanges 53, 61 normally extend above top portion 56, as is illustrated in FIG. 9. The length of the cleat is the distance from shingle portion 11 to thebackbend (see'FIG. 4) measured along shingle body section 1.

When the roof is being assembled, abutting edges 63, 65 of adjacent flanges are forced between the lower flanges 53, 61 and the top member 56. The flanges bend down to grip the edges 63, 65 and hold them firmly in place. The felt sheet 67 underlays the cleat to provide complete waterproofing of the roof.- The back-extending terially increased. The panels are also electrically insulated from the flashings and vent pipes, thus making it particularly feasible to use materials such as aluminum and copper, which are extremely resistant to oxidation but quite susceptible to electrolytic decomposition.

. The;.invention allows for the use of standard steps,

.cedures, rather than sheet metal practice.

flashing, and procedures common to the roofing industry.

As the waterproofing is performed by the underlay rather than the metal surface and the ends of the metal are not cemented, locked or anchored, and the bottom locks move freely, the only anchor is the top, thus, expansion presents no problem. This provides an excellent recover roof over very rough surfaces, such as wood shingles.

As the abrasion is covered by the felt and any reverse flow of water is thrown into a felt-to-felt gasket, flashing can be made into existing projection with roofing pro- All flashings can be made with felt and metal without the use of mastics, which deteriorate and cause leakage.

Foot traffic will not damage [the roof. Should a person step on the lock or butt of a panel, the lock will be closed tighter. Water drainage is almost entirely over the panels. Water that does find its way under the panels (including condensation on the backside of the metallic sheath) will drain down over the felts into the re-entrant hook, through weep holes 12, and out over the panels to the ground. The nails that secure the nailing flanges to the roof deck are isolated from water contact so that it is not possible for water to penetrate the felt through the nail perforations.

A further advantage of the invention is that very thin metal can be used for the panels to minimize the cost of manufacture and installation.

From the above description, the importance of the angle between the downwardly extending and back-extending portions of the re-entrant hook can be readily appreciated. The angle must be small enough to hold tension on the panel yet large enough to permit interlocking between panels.

The invention is not necessarily to be restricted to the specific structural details or arrangement of parts herein set forth, as various modifications thereof may be effected without departing from the spirit and scope of the invention.

What is claimed is: 1 r

l. A roof structure for covering a substantially continuous roof deck, comprising:

a plurality of substantially rectangular sheets of resilient, pliable, waterproof roofing material on said roof deck partially overlapping each other at spaced intervals going up said-roof deck, each upper sheet overlapping a portion of the immediately lower sheet;

a plurality of sheet metal panels covering said sheets and interconnecting lower edges of said sheets, each of said panels having a body portion terminating in a downwardly extending re-entrant hook along the lower edge thereof and in a re-entrant notch portion along the upper edge thereof, each re-entrant hook engaging the re-entrant notch portion of the next lower panel, said re-entrant notch portion being formed as an S-bend with the upper end of the S- bend terminating in anailing flange extending beyond the notch;

the topmost overlapping sheet covered by a given panel extending'over thenailingflange of the-panel immediately below said given panel and pressed between the upper'end of the S-bend of said panel immediately below andthe lower surface of the body portion of said given panel into the re-entrant hook of the given panel;

said nailing flange being nailed to the sheets thereunder and to the roof deck; the normal thickness of the sheets being at least the minimum distance between the body portion of one panel and the upper end of the S-bend of the-next lower panel interconnected therewith whereby a given sheet is compressed between said body portion of onepanel and said upper end of the S-bend of the next lowerpanel.

2.-A roof structure as claimed in claim wherein abutting, upwardly extending edges of adjacent panels are connected together by cleats comprising spaced apart verti.

cal webbed sections, an upper crosshead section connected toboth of said ventical web sections and extending outwardly therefrom, and first and second flanges respectively connected to the lower ends of said first and second vertical web sections and extending upwardly and outwardly therefrom beyond and above the extremities of the crosshead section, each of said flanges fitting be tween the body portions of said adjacent panels and the resilient, pliable, waterproof roofing material thereunder, the length of said cleats being substantially the length of the body section of said adjacent panels.

3. In a roof structure for covering a substantially continuous roof deck, comprising:

a pluralityof substantially rectangular sheets of resilient, pliable, waterproof roofing material on said roof deck partially overlapping each other at spaced intervals going up said roof deck, each upper sheet overlapping a portion of the immediately lower sheet;

a plurality of sheet metal panels covering said sheets and interconnecting loweredges of said sheets, each of said sheet metal panels terminating in a re-entrant hook along one edge thereof and having a re-entrant notch portion along an opposite edge thereof; each said re-entrant hook engaging the re-entrant notch portion of the next lower panel, and comprising a downwardly extending portion forming an angle of substantially 85 with the body of the sheet metal panel, and an upwardly-extending portion at the lower edge of said downwardly extending portion, said upwardlyaextending portion forming an angle of approximately 80? with said downwardly extending portion; a

said re-entrant notch portion being formed as an S-bend with the upper end of the S-bend providing an outwardly-extending nailing flange along the top edge of the body portiongsaid nailing flange being nailed to sheets of resilient,

pliable, waterproof roofing material thereunder and to the roof deck;

the topmost overlapping sheet covered by a given panel extending over said nailing flange andsaid re-entrant notch portion of the panel immediately below said given panel and the nails therethrough, into the reentrant hook of the given panel, and having a normal thickness which is at least the minimum initial dis tance between the body portion of said given panel and the upper leg of the S-bend ofthe next lower panel interconnected therewith, whereby said top most overlapping sheet is compressed between said body portion of said given panel and the upper leg of the S-bend of said next lower panel.

4. A roof structure as claimed in claim 3 wherein abutting, upwardly extending edges of adjacent panelsare connected together by cleats comprising spaced apart vertical webbed sections, an upper crosshead section connected to both of'said vertical web sections and extending outwardly therefrom, and first and second flanges respectively connected to the lower ends of said first and 5. A roof structure for covering a substantially continuous roof deck, comprising:

a plurality of substantially rectangular sheets of pliable,

waterproof roofing material on said roof deck partially overlapping each other at spaced intervals going up said roof deck, each upper sheet overlapping a portion of the immediately lower sheet;

a plurality of sheet metal panels covering said sheets and interconnecting lower edges of said sheets, each of said panels having a body portion terminating in a downwardly extending re-entrant hook along the lower edge thereof and in a re-entrant notch portion along the upper edge thereof, said re-entrant hook engaging the re-entrant notch portion of a similarly constructed next lower panel, and comprising a down- -wardly extending portion forming an angle of substantially with the body of the sheet metal member, and an upwardly-extending portion along the lower edge of said downwardly extending portion forming an angle of approximately 80 with said downwardly extending portion;

said re-entrant notch portion being formed as an S-bend with a short radius substantially 180 lower bend and a short radius substantially 200 upper bend, the upper bent section terminating in a nailing flange extending beyond the notch that receives the reentrant hook of the next upper panel member, said nailing flange being nailed to the sheets'thereunder and to the roof deck;

the distance between the body portion of one sheet metal panel and the upper leg of the tE-bend of the next lower panel being less than the normal thickness of the pliable sheet of roofing material therebetween whereby said pliable sheet of roofing material therebetween is compressed between said body portion of said one sheet metal panel and said upper leg of the iii-bend of the next lower panel.

6. A roof structure as set forth in claim 5 wherein abutting, upwardly extending edges of adjacent panels are connected together by cleats comprising spaced apart vertical webbed sections, an upper crosshead section connected to both of said vertical web sections and extending outwardly therefrom, and first and second flanges respectively connected to the lower ends of said first and second vertical web sections and extending upwardly and outwardly therefrom beyond and above the extremities of the crosshead section, each of said flanges fitting between the body portions of said adjacent panels and the sheet of waterproof roofing material thereunder, the length of said cleats being substantially the length of the body section of said adjacent panels.

References rCited-by the Examiner UNITED STATES PATENTS 'ARL l. WITMER, Primary Examiner. JACOB L. NACKENOFF, Examiner. 

1. A ROOF STRUCTURE FOR COVERING A SUBSTANTIALLY CONTINUOUS ROOF DECK, COMPRISING: A PLURALITY OF SUBSTANTIALLY RECTANGULAR SHEETS OF RESILIENT, PLIABLE, WATERPROOF ROOFING MATERIAL ON SAID ROOF DECK PARTIALLY OVERLAPPING EACH OTHER AT SPACED INTERVALS GOING UP SAID ROOF DECK, EACH UPPER SHEET OVERLAPPING A PORTION OF THE IMMEDIATELY LOWER SHEET; A PLURALITY OF SHEET METAL PANELS COVERING SAID SHEETS AND INTERCONNECTING LOWER EDGES OF SAID SHEETS, EACH OF SAID PANELS HAVING A BODY PORTION TERMINATING IN A DOWNWARDLY EXTENDING RE-ENTRANT HOOK ALONG THE LOWER EDGE THEREOF AND IN A RE-ENTRANT NOTCH PORTION ALONG THE UPPER EDGE THEREOF, EACH RE-ENTRANT HOOK ENGAGING THE RE-ENTRANT NOTCH PORTION OF THE NEXT LOWER PANEL, SAID RE-ENTRANT NOTCH PORTION BEING FORMED AS AN 8-BEND WITH THE UPPER END OF THE 8BEND TERMINATING IN A NAILING FLANGE EXTENDING BEYOND THE NOTCH; THE TOPMOST OVERLAPPING SHEET COVERED BY A GIVEN PANEL EXTENDING OVER THE NAILING FLANGE OF THE PANEL IMMEDIATELY BELOW SAID GIVEN PANEL AND PRESSED BETWEEN THE UPPER END OF THE 8-BEND OF SAID PANEL IMMEDIATELY BELOW AND THE LOWER SURFACE OF THE BODY PORTION OF SAID GIVEN PANEL INTO THE RE-ENTRANT HOOK OF THE GIVEN PANEL; SAID NAILING FLANGE BEING NAILED TO THE SHEETS THEREUNDER AND TO THE ROOF DECK; THE NORMAL THICKNESS OF THE SHEETS BEING AT LEAST THE MINIMUM DISTANCE BETWEEN THE BODY PORTION OF ONE PANEL AND THE UPPER END OF THE 8-BEND OF THE NEXT LOWER PANEL INTERCONNECTED THEREWITH WHEREBY A GIVEN SHEET IS COMPRESSED BETWEEN SAID BODY PORTION OF ONE PANEL AND SAID UPPER END OF THE 8-BEND OF THE NEXT LOWER PANEL. 